Ultrasonic Emergency Stop Control for Remote Machine Shutdown
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Solution Overview
Problem
Existing machine safety systems, particularly in industrial settings, face challenges in effectively and efficiently interrupting the operation of machinery, especially in emergency situations, to prevent accidents and ensure safety.
Innovation Solution
The use of acoustic signals, specifically ultrasonic signals with distinct tones, to remotely control the operation of machines. These signals are received by a tuned receiver on the machine, which alters its operation upon detecting a specific signature of tones, allowing for emergency stops or other operational changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If acoustic signals are used to remotely control machine operation, then safety and ease of operation are improved, but device complexity increases due to addition of emitter, receiver, and signal processing components
Solution Approach 1:
The patent replaces traditional mechanical emergency stop systems (physical buttons, switches, and circuits) with an acoustic signal-based control system. An emitter generates acoustic signals containing encoded commands, a receiver detects these signals, and a controller processes them to alter machine operation. This substitution eliminates the need for physical contact with control devices, enabling remote operation while maintaining safety functionality.
2Reliability
If acoustic signals with distinct tones are used for remote control, then reliability of emergency stop function is improved, but difficulty of detecting and measuring increases due to signal discrimination requirements
Solution Approach 1:
The patent segments the control signal into multiple distinct acoustic tones, where each tone or combination of tones represents a specific command or state. The receiver and controller are configured to detect and discriminate between these different tones, allowing reliable identification of emergency stop commands versus other operational signals. This segmentation enables robust signal recognition even in noisy environments.
Solution Approach 2:
The patent uses different acoustic frequencies (analogous to color changes in optical systems) to encode different control commands. By assigning specific frequency ranges or tone combinations to different functions (e.g., emergency stop, operational control, status indication), the system enables reliable signal discrimination through frequency-based detection, making it easier to identify and respond to critical emergency signals.
3Productivity
If acoustic signals are used instead of traditional emergency stop mechanisms, then productivity is improved through continuous operation capability, but loss of information increases if signals are not properly recognized
Solution Approach 1:
The patent incorporates feedback mechanisms where the controller monitors received acoustic signals and confirms proper recognition and execution of commands. The system can verify signal integrity, discriminate between valid commands and noise, and provide status feedback to ensure the emergency stop function or other control actions are properly executed. This feedback loop prevents information loss by ensuring accurate signal recognition and response.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides a reliable and efficient means to interrupt machine operation in emergency situations, enhancing safety by allowing for remote control and reducing the risk of accidents caused by uncontrolled machinery.
Implementation Method 1
a receiver (e.g., an ultrasonic receiver) that is tuned to a particular frequency (or narrow range of frequencies within a specified band)
Data Source
AI summary
Systems and methods are disclosed for altering operation of a machine (e.g., bringing about an emergency stop). A device comprises an emitter configured to produce a first acoustic signal having a first tone and a second tone, wherein the first tone is different from the second tone. The device also includes an activation mechanism in communication with the emitter. The activation mechanism is configured to activate the emitter.